Smoking substitute consumable

ABSTRACT

The present disclosure relates to an HNB consumable comprising an aerosol-forming substrate, the consumable having an axial length extending perpendicularly to a non-rectangular transverse end face. The axial length of the aerosol-forming substrate is greater than 45% of the axial length of the consumable and/or the volume of the aerosol-forming substrate is greater than 45% of the volume of the consumable.

CROSS-REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE STATEMENT

This application is a non-provisional application claiming benefit to the international application no. PCT/EP2020/073564 filed on Aug. 21, 2020, which claims priority to EP 19193292.0 filed on Aug. 23, 2019 and EP 19193285.4 filed on Aug. 23, 2019, EP 19193272.2. The entire contents of each of the above-referenced applications are hereby incorporated herein by reference in their entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to a consumable for use in a smoking substitute system and particularly, although not exclusively, to a heat-not-burn (HNB) consumable.

BACKGROUND

The smoking of tobacco is generally considered to expose a smoker to potentially harmful substances. It is generally thought that a significant amount of the potentially harmful substances is generated through the heat caused by the burning and/or combustion of the tobacco and the constituents of the burnt tobacco in the tobacco smoke itself.

Conventional combustible smoking articles, such as cigarettes, typically comprise a cylindrical rod of tobacco comprising shreds of tobacco which is surrounded by a wrapper, and usually also a cylindrical filter axially aligned in an abutting relationship with the wrapped tobacco rod. The filter typically comprises a filtration material which is circumscribed by a plug wrap. The wrapped tobacco rod and the filter are joined together by a wrapped band of tipping paper that circumscribes the entire length of the filter and an adjacent portion of the wrapped tobacco rod. A conventional cigarette of this type is used by lighting the end opposite to the filter, and burning the tobacco rod. The smoker receives mainstream smoke into their mouth by drawing on the mouth end or filter end of the cigarette.

Combustion of organic material such as tobacco is known to produce tar and other potentially harmful by-products. There have been proposed various smoking substitute systems (or “substitute smoking systems”) in order to avoid the smoking of tobacco.

Such smoking substitute systems can form part of nicotine replacement therapies aimed at people who wish to stop smoking and overcome a dependence on nicotine.

Smoking substitute systems include electronic systems that permit a user to simulate the act of smoking by producing an aerosol (also referred to as a “vapor”) that is drawn into the lungs through the mouth (inhaled) and then exhaled. The inhaled aerosol typically bears nicotine and/or flavorings without, or with fewer of, the odor and health risks associated with traditional smoking.

In general, smoking substitute systems are intended to provide a substitute for the rituals of smoking, whilst providing the user with a similar experience and satisfaction to those experienced with traditional smoking and with combustible tobacco products. Some smoking substitute systems use smoking substitute articles that are designed to resemble a traditional cigarette and are cylindrical in form with a mouthpiece at one end.

The popularity and use of smoking substitute systems has grown rapidly in the past few years. Although originally marketed as an aid to assist habitual smokers wishing to quit tobacco smoking, consumers are increasingly viewing smoking substitute systems as desirable lifestyle accessories.

There are a number of different categories of smoking substitute systems, each utilizing a different smoking substitute approach.

One approach for a smoking substitute system is the so-called “heat not burn” (“HNB”) approach in which tobacco (rather than an “e-liquid”) is heated or warmed to release vapor. The tobacco may be leaf tobacco or reconstituted tobacco. The vapor may contain nicotine and/or flavorings. In the HNB approach the intention is that the tobacco is heated but not burned, i.e., the tobacco does not undergo combustion.

A typical HNB smoking substitute system may include a device and a consumable. The consumable may include the tobacco material. The device and consumable may be configured to be physically coupled together. In use, heat may be imparted to the tobacco material by a heating element of the device, wherein airflow through the tobacco material causes moisture in the tobacco material to be released as vapor. A vapor may also be formed from a carrier in the tobacco material (this carrier may for example include propylene glycol and/or vegetable glycerin) and additionally volatile compounds released from the tobacco. The released vapor may be entrained in the airflow drawn through the tobacco.

As the vapor passes through the consumable (entrained in the airflow) from an inlet to a mouthpiece (outlet), the vapor cools and condenses to form an aerosol for inhalation by the user. The aerosol will normally contain the volatile compounds.

In HNB smoking substitute systems, heating as opposed to burning the tobacco material is believed to cause fewer, or smaller quantities, of the more harmful compounds ordinarily produced during smoking. Consequently, the HNB approach may reduce the odor and/or health risks that can arise through the burning, combustion and pyrolytic degradation of tobacco.

There is a need for improved design of HNB consumables to enhance the user experience and improve the function of the HNB smoking substitute system.

The present disclosure has been devised in the light of the above considerations.

SUMMARY OF THE DISCLOSURE

At its most general, the present disclosure relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable that has an increased proportion (length and/or volume) of aerosol-forming substrate.

According to a first aspect, there is provided a HNB consumable comprising an aerosol-forming substrate, the consumable having an axial length extending perpendicularly to a non-rectangular transverse end face, wherein the axial length of the aerosol-forming substrate is greater than 45% of the axial length of the consumable and/or wherein the volume of the aerosol-forming substrate is greater than 45% of the volume of the consumable.

Most known HNB consumables typically have a length of around 45 or 48 mm with tobacco portion having a length of around 12 mm or 15 mm. Thus, the tobacco portion forms only around 20-32% of the length/volume of the consumable. By increasing the proportional volume of aerosol-forming substrate e.g., tobacco in the consumable, the consumable can provide a longer user experience without increasing the length of the consumable and thus without increasing the size (and thus manufacturing costs) of the consumable packaging.

The present disclosure also relates to an aerosol-forming article e.g., a smoking substitute article such as an HNB consumable that has an aspect ratio resulting in a reduced axial length relative to a dimension (e.g., diameter, minimum dimension perpendicular to the axial length or cross-sectional area) of a transverse end face.

According to a second aspect, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate, the article/consumable having an axial length extending perpendicularly to a transverse end face, wherein the aspect ratio of the axial length to a diameter of the transverse end face is between 6:1 and 1:1.

The aspect ratio of the axial length to a diameter of the transverse end face is preferably between 5:1 and 1:1 or 4:1 and 1:1 or 3:1 and 1:1 such as between 2.5:1 and 1.1 e.g., between 2:1 and 1:1.

According to a third aspect, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate, the article/consumable having an axial length extending perpendicularly to a non-rectangular transverse end face, wherein the aspect ratio of the axial length to the square root of the area of the transverse end face is between 7:1 and 1.1:1.

The aspect ratio of the axial length to the square root of the area of the transverse end face is preferably between 5.6:1 and 1.1:1 or 4.5:1 and 1.1:1 or 3.4:1 and 1.1:1 such as between 2.8:1 and 1.1:1 e.g., between 2.3:1 and 1.1:1.

According to a fourth aspect, there is provided an aerosol-forming article (e.g., a smoking substitute article such as an HNB consumable) comprising an aerosol-forming substrate, the article/consumable having an axial length extending perpendicularly to a non-rectangular transverse end face, wherein the aspect ratio of the axial length to the minimum dimension through the axial center of the transverse end face perpendicular to the axial length is between 6:1 and 1:1.

The aspect ratio of the axial length to the minimum dimension through the axial center of the transverse end face perpendicular to the axial length is preferably between 5:1 and 1:1 such as between 2.5:1 and 1.1 e.g., between 2:1 and 1:1.

Known aerosol-forming articles e.g., HNB consumables typically have a length greater than 45 mm (e.g., up to 84 mm, or 100 mm or even 120 mm) and a diameter of between 5 and 8 mm. Thus, these known articles/consumables typically have an aspect ratio of length to diameter significantly in excess of 6:1 (and up to nearly 17:1). Thus, these articles/consumables can be considered to be long and thin thus resembling conventional cigarettes. This has been previously considered desirable to meet user expectations and also to allow use of existing conventional cigarette manufacturing machinery.

The resulting dimensions lead to an article/consumable that can easily be damaged (e.g., broken or bent) during manufacture, transit/storage prior to use and, particularly, during insertion into a HNB device. The articles/consumables described in the above aspects have a relatively smaller axial length compared to the dimensions of the transverse end face and thus are shorter and stockier/stubbier than the known articles/consumables. This renders them less susceptible to damage than the known articles/consumables. Furthermore, the relative dimensions of the articles/consumables described herein means that the ratio of the axially-extending surface area of the article/consumable to the volume of the consumable/article is reduced meaning that a reduced area of wrapping paper is required to circumscribe the axially-extending surface thus resulting in reduced material/manufacturing costs.

Optional features will now be set out. These are applicable singly or in any combination with any aspect. For example, any two or more of the second to fourth aspects may be combined.

In preferred embodiments of the first aspect, the axial length/volume of the aerosol-forming substrate is greater than 50% of the axial length/volume of the consumable, e.g., greater than 60% or 65%.

The axial length/volume of the aerosol-forming substrate may be between 45 and 100% of the axial length/volume of the consumable, e.g., between 50 and 100% or between 60 and 90% such as between 60 and 80% or 60 and 70%.

The transverse end face is intended to describe a two-dimensional face extending in a plane perpendicular to the axial length. There will be two opposing transverse end faces at the opposing axial ends of the consumable, with the axial length extending therebetween. In the second aspect, the transverse end face is preferably substantially oval.

In the first, third and fourth aspects, the transverse end face may have a polygonal shape such as a triangle, square, pentagon, hexagon, octagon etc. shape.

In some embodiments, at least a portion of the perimeter of the transverse end face may be curved. The transverse end face may be substantially circular or oval (i.e., the perimeter of the transverse end face may be entirely curved so as to form a circle/oval). However, in the second to fourth aspects, the transverse end face is preferably non-circular i.e., preferably both non-rectangular and non-circular.

The transverse end face may comprise two convex portions which meet at opposing axially extending ridges such that the transverse end face is mandorla-/eye-/almond-shaped.

Alternatively, in the first, third and fourth aspects, only a portion (e.g., two opposing portions) of the perimeter of the transverse end face may be curved or rounded e.g., the perimeter of the transverse end face may comprise at least one (e.g., two opposing) convex or concave rounded portion(s). In these embodiments, the perimeter of the transverse end face comprises at least one linear portion. It may, for example, comprises two opposing e.g., two opposing parallel linear portions. The linear portions may be spaced by the opposing curved/rounded portions.

For example, the transverse end face may have a substantially obround shape or a truncated oval shape. Or it may have a shape where the convex portions of the obround shape are replaced by convex portions. In other embodiments, the perimeter of the transverse end face may comprise at least one (e.g., two opposing) convex portion(s) which take(s) the form of a curly bracket or brace i.e., “{“or”}”.

The article/consumable may have a constant transverse cross-sectional area (matching the area of the transverse end face) along the axial length.

The article consumable may have a constant transverse cross-sectional shape (matching the shape of the transverse end face) along the axial length.

The article/consumable may have a transverse cross-sectional area that varies along the axial length e.g., decreases along the axial length.

The article/consumable may have a transverse cross-sectional shape that varies along the axial length.

In some embodiments, the axial length of the consumable is less than 45 mm, e.g., less than 40 mm or less than 35 mm such as less than 30 mm or 25 mm. It may be less than 20 mm or 15 mm. The axial length may be greater than 5 or 10 mm.

The diameter or minimum distance through the axial center of the transverse end face perpendicular to the axial length may be greater than 7 mm e.g., between 7 and 10 mm, such as between 7 and 9 mm or 7 and 8 mm.

Accordingly, the area of the transverse end face is preferably greater than 38 mm² such as between 38 and 78.5 mm², such as between 38 and 63.6 mm² or 38 and 50.3 mm². The aerosol-forming article of the second to fourth aspects is preferably a heat-not-burn (HNB) consumable.

The article/consumable comprises an aerosol-forming substrate which is capable of being heated to release at least one volatile compound that can form an aerosol. The aerosol-forming substrate may be located at the upstream end of the consumable.

As used herein, the terms “upstream” and “downstream” are intended to refer to the flow direction of the vapor/aerosol i.e., with the downstream end of the article/consumable being the mouth end or outlet where the aerosol exits the consumable for inhalation by the user. The upstream end of the article/consumable is the opposing end to the downstream end.

The aerosol-forming substrate may have an axial length of less than 45 mm, e.g., less than 40 mm or less than 35 mm such as less than 30 mm or 25 mm. It may be less than 20 mm or 15 mm. The axial length may be greater than 10 mm. For example, it may be around 12 mm.

In order to generate an aerosol, the aerosol-forming substrate comprises at least one volatile compound that is intended to be vaporized/aerosolized and that may provide the user with a recreational and/or medicinal effect when inhaled. Suitable chemical and/or physiologically active volatile compounds include the group consisting of: nicotine, cocaine, THC, caffeine, cannaboids, opiates and opioids, cathine and cathinone, kavalactones, mysticin, beta-carboline alkaloids, salvinorin A together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

The aerosol-forming substrate may comprise plant material. The plant material may comprise least one plant material selected from the list including Amaranthus dubius, Arctostaphylos uva-ursi (Bearberry), Argemone mexicana, Arnica, Artemisia vulgaris, Yellow Tees, Galea zacatechichi, Canavalia maritima (Baybean), Cannabis, Cecropia mexicana (Guamura), Cestrum noctumum, Cynoglossum virginianum (wild comfrey), Cytisus scoparius, Damiana, Entada rheedii, Eschscholzia califomica (California Poppy), Fittonia albivenis, Hippobroma longiflora, Humulus japonica (Japanese Hops), Humulus lupulus (Hops), Lactuca virosa (Lettuce Opium), Laggera alata, Leonotis leonurus, Leonurus cardiaca (Motherwort), Leonurus sibiricus (Honeyweed), Lobelia cardinalis, Lobelia inflata (Indian-tobacco), Lobelia siphilitica, Nepeta cataria (Catnip), Nicotiana species (Tobacco), Nymphaea alba (White Lily), Nymphaea caerulea (Blue Lily), Opium poppy, Passiflora incamata (Passionflower), Pedicularis densiflora (Indian Warrior), Pedicularis groenlandica (Elephant's Head), Salvia divinorum, Salvia dorrii (Tobacco Sage), Salvia species (Sage), Scutellaria galericulata, Scutellaria lateriflora, Scutellaria nana, Scutellaria species (Skullcap), Sida acuta (Wireweed), Sida rhombifolia, Silene capensis, Syzygium aromaticum (Clove), Tagetes lucida (Mexican Tarragon), Tarchonanthus camphoratus, Tumera diffusa (Damiana), Verbascum (Mullein), Zamia latifolia (Maconha Brava) together with any combinations, functional equivalents to, and/or synthetic alternatives of the foregoing.

Preferably, the plant material is tobacco. Any type of tobacco may be used. This includes, but is not limited to, flue-cured tobacco, burley tobacco, Maryland Tobacco, dark-air cured tobacco, oriental tobacco, dark-fired tobacco, perique tobacco and rustica tobacco. This also includes blends of the above-mentioned tobaccos.

Any suitable parts of the tobacco plant may be used. This includes leaves, stems, roots, bark, seeds and flowers.

The tobacco may comprise one or more of leaf tobacco, stem tobacco, tobacco powder, tobacco dust, tobacco derivatives, expanded tobacco, homogenized tobacco, shredded tobacco, extruded tobacco, cut rag tobacco and/or reconstituted tobacco (e.g., slurry recon or paper recon).

The aerosol-forming substrate may comprise one or more additives selected from humectants, flavorants, fillers and binders,

Humectants are provided as vapor generators—the resulting vapor helps carry the volatile active compounds and increases visible vapor. Suitable humectants include polyhydric alcohols (e.g., propylene glycol (PG), methylene glycol, 1,2-butane diol and vegetable glycerin (VG)) and their esters (e.g., glycerol mono-, di- or tri-acetate). They may be present in the aerosol-forming substrate in an amount between 1 and 50 wt %.

The humectant content of the aerosol-forming substrate may have a lower limit of at least 1% by weight of the plant material, such as at least 2 wt %, such as at least 5 wt %, such as at least 10 wt %, such as at least 20 wt %, such as at least 30 wt %, or such as least 40 wt %.

The humectant content of the aerosol-forming substrate may have an upper limit of at most 50% by weight of the plant material, such as at most 40 wt %, such as at most 30 wt %, or such as at most 20 wt %.

Preferably, the humectant content is 1 to 40 wt % of the aerosol-forming substrate, such as 1 to 20 wt %.

Suitable binders are known in the art and may comprise starches and/or cellulosic binders such as methyl cellulose—ethyl cellulose, hydroxypropyl cellulose, hydroxyethyl cellulose and methyl cellulose, gums such as xanthan, guar, Arabic and/or locust bean gum, organic acids and their salts such as alginic acid/sodium alginate, agar and pectins.

Preferably the binder content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 8 wt %.

Suitable fillers are known in the art and may comprise fibrous fillers such as cellulose fibers.

Preferably, the filler content is 5 to 10 wt % of the aerosol-forming substrate e.g., around 6 to 9 wt %.

The flavorant may be provided in solid or liquid form. It may include menthol, licorice, chocolate, fruit flavor (including e.g., citrus, cherry etc.), vanilla, spice (e.g., ginger, cinnamon) and tobacco flavor. The flavorant may be evenly dispersed throughout the aerosol-forming substrate or may be provided in isolated locations and/or varying concentrations throughout the aerosol-forming substrate.

The aerosol-forming substrate may be circumscribed by a wrapping layer e.g., a paper wrapping layer. The wrapping layer may overlie an inner foil layer or may comprise a paper/foil laminate (with the foil innermost).

In some embodiments, the aerosol-forming substrate may comprise a recess or bore extending axially from the downstream transverse end face into the plant material for receipt of a heating element as described below. The recess/bore may extend the full or only a portion of the axial length of the substrate.

The article/consumable may comprise at least one further element which may be downstream of the substrate.

The further element may be a porous element. The porous element may have a porosity such that it at least partly blocks the passage (filters out) at least one of the component of the aerosol/vapor. Thus the at least one porous element may be a filter element.

The or each filter element may be comprised of cellulose acetate or polypropylene tow, activated charcoal or paper, for example. The or each filter element may be circumscribed with a plug wrap e.g., a paper plug wrap.

In other embodiments, the porous element may have a density/porosity/permeability such that it is permeable to (allows passage of) all components of the aerosol/vapor.

In yet further embodiments, the further element may be a porous or solid element having a hollow bore for the passage of the aerosol/vapor.

In yet further embodiments, instead of or in addition to the porous/filter/hollow bore element, the further element may comprise a spacer element that defines a space or cavity or chamber between the aerosol-forming substrate and the downstream end of the consumable. The spacer acts to allow both cooling and mixing of the aerosol. The spacer element may comprise a cardboard or plastic tube. The spacer element may be at least partly (e.g., entirely) circumscribed by the (paper) wrapping layer.

In even further embodiments, instead of or in addition to the porous/filter/hollow bore/spacer element, the further element may comprise an aerosol-cooling element which is adapted to cool the aerosol generated from the aerosol-forming substrate (by heat exchange) before being inhaled by the user.

The aerosol-cooling element may be formed of a plastics material selected from the group consisting of polylactic acid (PLA), polyvinyl chloride (PVC), polyethylene (PE) and polyethylene terephthalate (PET). The aerosol-cooling element may be formed of a crimped/gathered sheet of material to form a structure having a high surface area with a plurality of longitudinal channels to maximize heat exchange and cooling of the aerosol.

The further element(s) may have a transverse cross-section matching the shape of the transverse end face. The or each further element may have a diameter/minimum dimension/cross-sectional area substantially matching that of the aerosol-forming substrate (with or without its associated wrapping layer).

There may be a terminal element at the downstream/mouth end of the consumable which may be as described above e.g., there may be a terminal filter/porous/hollow bore/spacer/cooling element.

The axial length of the or each further element may be less than 12 mm, e.g., less than 15 mm or less than 10 mm such as between 2 mm and 10 mm, for example between 3 and 7 mm e.g., between 3 and 5 mm or 3 and 4 mm.

The or at least one of the further elements e.g., the terminal filter element may include a capsule e.g., a crushable capsule (crush-ball) containing a liquid flavorant e.g., any of the flavorants listed above. The capsule can be crushed by the user during smoking of the consumable to release the flavorant. The capsule may be located at the axial center of the terminal filter element.

In a fifth aspect, there is provided a smoking substitute system comprising an article/a consumable according to any one of the first to fourth aspects and a device comprising a heating element.

The device may be a HNB device i.e., a device adapted to heat but not combust the aerosol-forming substrate.

The device may comprise a main body for housing the heating element. The heating element may comprise an elongated e.g., rod, tube-shaped or blade heating element. The heating element may project into or surround a cavity within the main body for receiving the consumable described above.

The device (e.g., the main body) may further comprise an electrical power supply e.g., a (rechargeable) battery for powering the heating element. It may further comprise a control unit to control the supply of power to the heating element.

In a sixth aspect, there is provided a method of using a smoking substitute system according to the fifth aspect, the method comprising:

-   -   inserting the article/consumable into the device; and heating         the article/consumable using the heating element.

In some embodiments, the method comprises inserting the article/consumable into a cavity within the main body and penetrating the article/consumable with the heating element upon insertion of the article/consumable. For example, the heating element may penetrate the aerosol-forming substrate in the article/consumable.

The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects may be applied to any other aspect. Furthermore, except where mutually exclusive, any feature or parameter described herein may be applied to any aspect and/or combined with any other feature or parameter described herein.

SUMMARY OF THE FIGURES

So that the disclosure may be understood, and so that further aspects and features thereof may be appreciated, embodiments illustrating the principles of the disclosure will now be discussed in further detail with reference to the accompanying figures, in which:

FIG. 1 shows a first embodiment of an HNB consumable;

FIG. 2 shows a second embodiment of an HNB consumable;

FIG. 3 shows a third embodiment of an HNB consumable;

FIG. 4 shows the first embodiment within a device forming an HNB system; and

FIGS. 5A-5I shows alternative shapes for the transverse end face.

DETAILED DESCRIPTION OF THE FIGURES

As shown in FIG. 1, the HNB consumable 1 comprises an aerosol-forming substrate 2 at the upstream end of the consumable 1.

The aerosol-forming substrate comprises reconstituted tobacco which includes nicotine as a volatile compound.

The aerosol-forming substrate 2 is dosed either with 21 wt % of a humectant such as propylene glycol (PG) or vegetable glycerin (VG) and 8 wt % guar gum or with just 20% of the humectant.

The aerosol-forming substrate 2 is formed in a substantially cylindrical shape such that the consumable resembles a conventional cigarette. It has a circular transverse end face 5 having diameter of 7.1 mm and an axial length of 12 mm.

The aerosol-forming substrate 2 is circumscribed by a paper wrapping layer 4.

The consumable 1 comprises an upstream spacer element 3 formed of a cardboard tube having an axial length of either 6 mm or 4 mm.

Thus, the overall length of the consumable is either 18 mm in which case the length/volume of the substrate is 66.7% of the total length/volume, or the overall length is 16 mm. This gives an aspect ratio of the length to diameter of 2.25:1 and an aspect ratio of length to the square root of the area of the transverse end face 5 of 2.0:1.

FIG. 2 shows a second embodiment of a consumable 1′ which is the same as that shown in FIG. 1 except that there is a terminal filter element 6 having an axial length of 10 mm.

Thus, the overall length of the consumable is 22 mm. The length/volume of the substrate is 54.5% of the total length/volume. This gives an aspect ratio of the length to diameter of 3.1:1 and an aspect ratio of length to the square root of the area of the transverse end face 5 of 3.5:1.

FIG. 3 shows a third embodiment of a consumable 1″ which is the same as that shown in FIG. 2 except that the filter element 6 comprises a crushable capsule 7 (crush-ball) having a shell wall containing a liquid menthol or cherry or vanilla flavorant. The capsule 8 is spherical and has a diameter of 3.5 mm. It is positioned within the axial center of the terminal filter portion 6.

FIG. 4 shows the first embodiment inserted into an HNB device 10 comprising a rod-shaped heating element 22. The heating element 22 projects into a cavity 11 within the main body 12 of the device.

The consumable 1 is inserted into the cavity 11 of the main body 12 of the device 10 such that the heating rod penetrates the aerosol-forming substrate 2. The reduced axial length compared to the dimensions of the transverse end face 5 (into which the heating element 22 is inserted) helps reduce bending and breakage of the consumable 1 as it is inserted into the device 10.

Heating of the reconstituted tobacco in the aerosol-forming substrate 2 is effected by powering the heating element 22 (e.g., with a rechargeable battery (not shown)). As the tobacco is heated, moisture and volatile compound (e.g., nicotine) within the tobacco and the humectant are released as a vapor and entrained within an airflow generated by inhalation by the user at the terminal filter portion 5.

As the vapor cools within the upstream filter element 4 and the cardboard spacer tube 6, it condenses to form an aerosol containing the volatile compounds for inhalation by the user.

FIGS. 5A-5I show alternative shapes for the transverse end face such as an oval shape (5D), a truncated oval shape (5E), an obround shape (5A) a triangular shape (5H) and a hexagonal shape (51).

While the disclosure has been described in conjunction with the exemplary embodiments described above, many equivalent modifications and variations will be apparent to those skilled in the art when given this disclosure. Accordingly, the exemplary embodiments of the disclosure set forth above are considered to be illustrative and not limiting. Various changes to the described embodiments may be made without departing from the scope of the disclosure.

Throughout this specification, including the claims which follow, unless the context requires otherwise, the words “have”, “comprise”, and “include”, and variations such as “having”, “comprises”, “comprising”, and “including” will be understood to imply the inclusion of a stated integer or step or group of integers or steps but not the exclusion of any other integer or step or group of integers or steps.

Preferred aspects and embodiments are set out in the following numbered paragraphs:

1. An aerosol-forming article comprising an aerosol-forming substrate, the article having an axial length extending perpendicularly to a non-rectangular (and preferably non-circular) transverse end face, wherein:

-   -   a) the aspect ratio of the axial length to a diameter of the         transverse end face is between 6:1 and 1:1; and/or     -   b) the aspect ratio of the axial length to a minimum dimension         through the axial center of the transverse end face         perpendicular to the axial length is between 6:1 and 1:1; and/or     -   c) the aspect ratio of the axial length to the square root of         the area of the transverse end face is between 7:1 and 1.1:1.

2. An article according to paragraph 1 wherein the aspect ratio of the axial length to the diameter of the transverse end face or to the minimum dimension through the axial center of the transverse end face perpendicular to the axial length is between 5:1 and 1:1.

3. An article according to paragraph 2 wherein the aspect ratio of the axial length to the diameter of the transverse end face or to the minimum dimension through the axial center of the transverse end face perpendicular to the axial length is between 2.5:1 and 1.1.

4. An article according to paragraph 1 wherein the aspect ratio of the axial length to the square root of the area of the transverse end face is between 5.6:1.

5. An article according to paragraph 1 wherein the aspect ratio of the axial length to the square root of the area of the transverse end face is between 2.8:1 and 1.1:1.

6. An article according to any one of the preceding paragraphs wherein the axial length of the consumable is less than 40 mm.

7. An article according to paragraph 6 wherein the axial length of the consumable is less than 25 mm.

8. An article according to paragraph 7 wherein the axial length of the consumable is less than 18 mm.

9. An article according to any one of the preceding paragraphs wherein the perimeter of the transverse end face comprises at least one curved portion.

10. An article according to paragraph 9 wherein the transverse end face is substantially circular or oval.

11. An article according to any one of the preceding paragraphs wherein the article is a heat-not-burn (HNB) consumable.

12. An article according to any one of the preceding paragraphs further comprising at least one element selected from a filter element, a spacer element, a hollow bore element or a cooling element.

13. A system comprising a smoking substitute article according to any one of the preceding paragraphs and a device comprising a heating element.

14. A system according to paragraph 13 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.

15. A method of using the system according to paragraph 13 or 14, the method comprising:

-   -   inserting the article into the device; and     -   heating the article using the heating element. 

What is claimed is:
 1. A HNB consumable comprising an aerosol-forming substrate, the consumable having an axial length extending perpendicularly to a non-rectangular transverse end face, wherein the volume of the aerosol-forming substrate is greater than 45% of the volume of the consumable.
 2. A consumable according to claim 1 wherein the volume of the aerosol-forming substrate is greater than 50% of the axial length/volume of the consumable.
 3. A consumable according to claim 2 wherein the axial volume of the aerosol-forming substrate is greater than 65% of the axial length/volume of the consumable.
 4. A consumable according to claim 1 or 2 wherein the axial volume of the aerosol-forming substrate is between 50 and 70% of the axial length/volume of the consumable.
 5. A consumable according to any one of the preceding claims wherein the transverse end face has a polygonal shape such as a triangle, square, pentagon, hexagon, octagon etc. shape.
 6. A consumable according to any one of claims 1 to 4 wherein at least a portion of the perimeter of the transverse end face is curved.
 7. A consumable according to claim 6 wherein the transverse end face is substantially circular or oval.
 8. A consumable according to any one of claims 1 to 7 having a transverse cross-sectional area that varies along the axial length.
 9. A consumable according to any one of the preceding claims having a transverse cross-sectional shape that varies along the axial length.
 10. A consumable according to any one of the preceding claims wherein the axial length of the consumable is less than 45 mm.
 11. A consumable according to any one of the preceding claims wherein the aerosol-forming substrate comprises a recess or bore extending axially from a downstream transverse end face.
 12. A consumable according to any one of the preceding claims further comprising at least one element selected from a filter element, a spacer element, a hollow bore element or a cooling element.
 13. A system comprising a smoking substitute article according to any one of the preceding claims and a device comprising a heating element.
 14. A system according to claim 13 wherein the device comprises a main body for housing the heating element and the heating element comprises an elongated heating element.
 15. A method of using the system according to claim 13 or 14, the method comprising: inserting the article into the device; and heating the article using the heating element. 